Description
This listing is for a reconditioned BorgWarner BV39 turbocharger, specifically engineered for the Audi A3 TDI 140HP models fitted with the BKD engine, manufactured between 2003 and 2009. It directly replaces original equipment part number 54399880048 and alternative 03G253019J.
The BV39 is a robust, variable geometry turbocharger commonly found across many VAG group diesel applications. This particular unit has undergone a meticulous, full reconditioning process at our Birmingham facility, ensuring it meets or exceeds original manufacturer specifications for performance and longevity. Our reconditioning procedure involves a complete strip-down, thorough cleaning of all components, detailed inspection for wear and damage, and the replacement of all critical worn parts with new, high-quality equivalents. The rotating assembly is precision balanced to exacting tolerances, and the variable geometry mechanism is calibrated and tested for optimal boost control before final assembly and quality checks.
Common failure modes for this BV39 unit when fitted to the BKD engine often include oil seal leaks, typically indicated by blue smoke emitted from the exhaust, signifying oil entering either the exhaust or intake system. Another frequent issue is wheel imbalance, which can manifest as excessive noise, reduced engine performance, and can ultimately lead to catastrophic failure of the turbocharger bearings and shaft. Carbon build-up within the variable geometry mechanism is also a prevalent problem, causing erratic boost control, over-boosting, under-boosting, and subsequent activation of the vehicle’s limp mode.
At Gap Turbos, we offer this reconditioned unit as an exchange service, meaning you return your old, failed turbocharger to us. We also provide brand new exchange units for certain applications if a new part is preferred. Our services extend to professional fitting at our workshop by experienced technicians. We always recommend a thorough engine system clean to address the root cause of the original turbo failure, particularly crucial for issues related to oil contamination or restricted oil supply, which can severely impact a new or reconditioned unit.
What this turbocharger fits
This BorgWarner BV39 turbocharger is specifically designed for the following vehicle application:
- Brand: Audi
- Model: A3 TDI
- Engine Code: BKD
- Horsepower: 140 HP
- Year Range: 2003 – 2009
- Fuel Type: Diesel
- Original Equipment (OE) Part Number: 54399880048
- Alternative Part Number(s): 03G253019J
Ensuring your vehicle’s details match these specifications is crucial for correct fitment. Please verify the part numbers on your existing turbocharger before ordering to avoid fitment issues.
For a precise quote or to discuss your specific requirements, please contact us directly. All our reconditioned turbochargers come with a comprehensive warranty for your peace of mind, reflecting our confidence in the quality of our work.
Specifications
| Frame | BV39 |
|---|---|
| Engine code(s) | BKD |
| Horsepower | 140hp |
| Year range | 2003-2009 |
| Fuel | Diesel |
| OE number | 54399880048 |
| Alternative number(s) | 03G253019J |
| Condition | Reconditioned |
Vehicle fitment
- Audi A3 TDI
Common faults & troubleshooting
[‘* Blue smoke from exhaust: Likely indicates oil seal failure within the turbocharger, allowing oil into the exhaust system. Requires turbocharger replacement.’, ‘* Loss of power or limp mode: Often caused by carbon build-up in the variable geometry mechanism, leading to incorrect boost pressure. Inspect VGT actuator and mechanism for sticking.’, ‘* Whining or whistling noise: Can be a symptom of worn bearings or wheel imbalance within the turbocharger. Indicates impending turbocharger failure.’, ‘* Excessive oil consumption without visible leaks: Check for oil in the intercooler or exhaust, suggesting internal turbocharger oil leaks.’, ‘* Black smoke under acceleration: May indicate over-fuelling or insufficient air, potentially due to a faulty turbocharger not providing adequate boost. Check boost pipes for leaks and turbocharger for free movement.’]
Fitting notes for this unit
[‘* Always replace the oil feed pipe and drain pipe gaskets to prevent oil leaks and ensure proper oil flow.’, ‘* Ensure the engine oil and oil filter are replaced with the correct specification for the BKD engine before fitting the new turbocharger.’, ‘* Thoroughly clean the intercooler and associated pipework to remove any debris or oil contamination from the previous turbo failure.’, ‘* Prime the new turbocharger with clean engine oil through the oil feed hole before starting the engine to ensure initial lubrication.’, “* Torque all exhaust manifold and downpipe bolts to the manufacturer’s specified settings to prevent leaks and stress on the turbo housing.”, ‘* After installation, idle the engine for several minutes before revving to allow oil pressure to build and circulate fully through the new turbocharger.’]
Alternative part numbers
This turbo is also referenced by:
03G253019J— Audi Turbocharger OEM 03G253019J (Audi A3 TDI, BKD, 140hp)
Need this turbo cleaned or reconditioned?
Many turbo faults are actuator-only or VNT vane carbon buildup, not a failed core. We strip, ultrasonically clean, rebuild, and balance to OEM tolerances with a 24-month parts and labour warranty.
Turbo Reconditioning →Need to speak to a turbocharger expert?
Send your reg, a photo of the existing part, and a brief description of the fault. We will respond same day.
Contact Our Experts →
Reviews
There are no reviews yet.